Model S1F Metallic Design Level 1

Transcription

SERVICE & OPERATING MANUAL
See page 2
for ATEX ratings.
Model S1F Metallic Design Level 1
Table of Contents
CE
U.S. Patent #
5,996,627
Other U.S. Patents
Applied for
Engineering Data and Temperature Limitations..................................................... 1
Air Valve Drawing, Parts List, Service Instructions (Cast Iron Centers Only) ...... 16
Explanation of Pump Nomenclature ...................................................................... 2
Air Valve w/Stroke Indicator Drawing, Parts List, Service Instructions ................ 17
Performance Curve................................................................................................ 3
Solenoid Shifted Air Valve Drawing ..................................................................... 18
Dimensions ........................................................................................................... 4
Solenoid Shifted Air Valve Parts List ................................................................... 18
Metric Dimensions ................................................................................................ 5
Solenoid Shifted Air Valve Option ........................................................................ 19
Principle of Pump Operation.................................................................................. 6
Diaphragm Service Drawing, with Overlay .......................................................... 20
Installation and Start-Up ........................................................................................ 6
Diaphragm Service Drawing, Non-Overlay .......................................................... 20
Air Supply .............................................................................................................. 6
Diaphragm Servicing ........................................................................................... 21
Air Valve Lubrication .............................................................................................. 6
Overlay Diaphragm Servicing ............................................................................. 21
Air Line Moisture.................................................................................................... 6
Pilot Valve Servicing, Assembly Drawing & Parts List ......................................... 22
Air Inlet and Priming .............................................................................................. 6
Actuator Plunger Servicing .................................................................................. 23
Between Uses ....................................................................................................... 6
Check Valve Servicing ......................................................................................... 24
Installation Guide ................................................................................................... 7
Check Valve Drawing ........................................................................................... 24
Troubleshooting ..................................................................................................... 8
Optional Muffler Configurations ........................................................................... 25
Warranty ................................................................................................................ 8
Optional Muffler Configuration Drawing ............................................................... 25
Recycling ............................................................................................................... 9
Pumping Hazardous Liquids................................................................................ 26
Important Safety Information ................................................................................. 9
Converting Pump for Piping Exhaust Air ............................................................. 26
Material Codes .................................................................................................... 10
Converted Exhaust Illustration............................................................................. 26
Composite Repair Parts Drawing ........................................................................ 12
Pulse Output Kit Drawing .................................................................................... 27
Available Service and Conversion Kits ................................................................ 12
Pulse Output Kit Options ..................................................................................... 27
Composite Repair Parts List ............................................................................... 13
Grounding The Pump .......................................................................................... 28
Air Valve Drawing, Parts List, Service Instructions (Integral Muffler) ................... 14
CE Declaration of Conformity .............................................................................. 29
Air Valve Drawing, Parts List, Service Instructions .............................................. 15
s1fmdl1sm-REV0509
WARREN RUPP®, IDEX AODD, Inc. • A Unit of IDEX Corporation • 800 N. Main St., P.O. Box 1568, Mansfield, Ohio 44901-1568 USA
Telephone (419) 524-8388 • Fax (419) 522-7867 • www.warrenrupp.com
©Copyright 2009 IDEX AODD, Inc. All rights reserved.
See page 2
for ATEX ratings.
Quality System
ISO9001 Certified
CE
Environmental
Management System
ISO14001 Certified
Air Inlet Side View
Air Exhaust Side View
U.S. Patent #
5,996,627
Other U.S. Patents
Applied for
S1F
Metallic
Design Level 1
Ball Valve
Air-Operated
Double Diaphragm Pump
ENGINEERING, PERFORMANCE
& CONSTRUCTION DATA
INTAKE/DISCHARGE PIPE SIZE
CAPACITY
AIR VALVE
SOLIDS-HANDLING
HEADS UP TO
DISPLACEMENT/STROKE
1" NPT (internal)
1" BSP Tapered (internal)
0 to 45 gallons per minute
(0 to 170 liters per minute)
No-lube, no-stall
design
Up to .25 in. (6mm)
125 psi or 289 ft. of water
(8.6 Kg/cm2 or 86 meters)
.11 Gallon / .42 liter
CAUTION! Operating temperature limitations are as follows:
Materials
Operating Temperatures
Maximum
Minimum
Nitrile: General purpose, oil-resistant. Shows good solvent, oil, water and hydraulic fluid resistance. Should not be used with highly polar solvents like
acetone and MEK, ozone, chlorinated hydrocarbons and nitro hydrocarbons.
190° F
88° C
-10° F
-23° C
EPDM: Shows very good water and chemical resistance. Has poor resistance to oil and solvents, but is fair in ketones and alcohols.
280° F
138° C
-40° F
-40° C
Neoprene: All purpose. Resistant to vegetable oil. Generally not affected by moderate chemicals, fats, greases and many oils and solvents. Generally
attacked by strong oxidizing acids, ketones, esters, nitro hydrocarbons and chlorinated aromatic hydrocarbons.
200° F
93° C
-10° F
-23° C
Santoprene®:: Injection molded thermoplastic elastomer with no fabric layer. Long mechanical flex life.
Excellent abrasion resistance.
275° F
135° C
-40° F
-40° C
Virgin PTFE: Chemically inert, virtually impervious. Very few chemicals are known to react chemically with PTFE- molten alkali metals, turbulent liquid or
gaseous fluorine and a few fluoro-chemicals such as chlorine trifluoride or oxygen difluoride which readily liberate free fluorine at elevated temperatures.
220° F
104° C
-35° F
-37° C
FKM (Fluorocarbon): Shows good resistance to a wide range of oils and solvents; especially all aliphatic, aromatic and halogenated hydrocarbons, acids,
animal and vegetable oils. Hot water or hot aqueous solutions (over 70°F) will attack FKM.
350° F
177° C
-40° F
-40° C
Polypropylene:
180° F
82° C
32° F
0° C
Polyethylene:
180° F
82° C
-35° F
-37° C
For specific applications, always consult the Warren Rupp Chemical Resistance Chart
SANDPIPER® pumps are designed to be powered only by compressed air.
s1fmdl1sm-REV0509
Model S1F Metallic Page 1
Explanation of Pump Nomenclature, S1F Metallic · Design Level 1· Ball Valve
Check
Valve
Type
B
B
B
B
B
B
B
B
B
B
B
MODEL
Pump Pump
Brand Size
S1FB1ABWANS000.
S
1F
S1FB1AIWANS000.
S
1F
S1FB1AGTANS000.
S
1F
S1FB1A1WANS000.
S
1F
S1FB1ACTANS000.
S
1F
S1FB1IBWANS000.
S
1F
S1FB1INWANS000.
S
1F
S1FB1I1WANS000.
S
1F
S1FB1ICTANS000.
S
1F
S1FB1IIWANS000.
S
1F
S1FB1SGTANS000.
S
1F
Design
Level
1
1
1
1
1
1
1
1
1
1
1
Wetted
Material
A
A
A
A
A
I
I
I
I
I
S
Diaphragm/
Check Valve
Materials
B
I
G
1
C
B
N
1
C
I
G
Check
Valve
Seat
W
W
T
W
T
W
W
W
T
W
T
Non-Wetted
Material
Porting
Options
Options
A
N
A
N
A
N
A
N
A
N
A
N
A
N
A
N
A
N
A
N
A
N
Pump Pump
Kit
Style Options Options
S
0
00.
S
0
00.
S
0
00.
S
0
00.
S
0
00.
S
0
00.
S
0
00.
S
0
00.
S
0
00.
S
0
00.
S
0
00.
Shipping
Weight
lbs. (kg)
28 (13)
28 (13)
28 (13)
28 (13)
28 (13)
46 (21)
46 (21)
46 (21)
46 (21)
46 (21)
43 (20)
Note: Models listed in the table are for reference only. See nomenclature below for other models.
Pump Brand
S= SANDPIPER®
Pump Size
1F=1"
Check Valve Type
B= Ball
Design Level
1= Design Level
Wetted Material
A= Aluminum
I = Cast Iron
S= Stainless Steel
H= Alloy C
(1)
Diaphragm Check Valve
Materials
1= Santoprene/Santoprene
B= Nitrile/Nitrile
C= FKM/PTFE
I = EPDM/Santoprene
G= PTFE-Neoprene/PTFE
N= Neoprene/Neoprene
Z= One-Piece Bonded/PTFE
Check Valve Seat
A= Aluminum
C= Carbon Steel
S= Stainless Steel
T= PTFE
W= UHMW
II 2GD T5
Note: Pumps are only ATEX
compliant when ordered
with pump option 6 or 7,
and kit option 0.
Non-Wetted Material Options
A= Painted Aluminum
I = Cast Iron
Y= Painted Aluminum with
Stainless Steel Hardware
Z= Cast Iron with
Stainless Steel Hardware
Porting Options
N= NPT Threads
B= BSP (Tapered) Threads
R= Raised Face 150#
Threaded ANSI Flange
Pump Style
S= Standard
(2)
II 2G Ex ia c IIC T5
II 2D c iaD 20 IP67 T100˚C
Note: Pumps ordered
with the options listed in
(1) to the left are ATEX
with kit option P1.
Pump Options
0= None
1= Sound Dampening Muffler
2= Mesh Muffler
3= High temperature Air
Valve w/Encapsulated
Muffler
Valve w/Sound
Dampening Muffler
Valve w/Mesh Muffler
6= Metal Muffler
7= Metal Muffler with
Grounding Cable
(3*)
Kit Options
00.= None
P0.= 10-30VDC Pulse Output Kit
P1.= Intrinsically-Safe 5-30VDC,
110/120VAC 220/240 VAC
Pulse Output Kit
P2.= 110/120 or 220/240VAC
Pulse Output Kit
E0.= Solenoid Kit with 24VDC Coil
E1.= Solenoid Kit with 24VDC
Explosion-Proof Coil
E2.= Solenoid Kit with 24VAC/12VDC Coil
E3.= Solenoid Kit with 12VDC
E4.= Solenoid Kit with 110VAC Coil
E5.= Solenoid Kit with 110VAC
E6.= Solenoid Kit with 220VAC Coil
II 2G EEx m c T5
II 2D c IP65 T100°C
Note: Pumps ordered with
the options listed in (1) to
the left are ATEX
with kit option A1, A2, A3,
or A4.
(4)
Kit Options continued
E7.= Solenoid Kit with 220VAC
E8.= Solenoid Kit with 110VAC, 50 Hz
E9.= Solenoid Kit with 230VAC, 50 Hz
SP.= Stroke Indicator Pins
A1.= Solenoid Kit with 12 VDC
A2.= Solenoid Kit with 24 VDC
A3.= Solenoid Kit with 110/120 VAC
50/60 Hz Explosion-Proof Coil
A4.= Solenoid Kit with 220/240 VAC
50/60 Hz Explosion-Proof Coil
IEC EEX m T4
Note: Pump models equipped with these
explosion-proof solenoid kit options E1,
E3, E5, E7, E8 or E9, are certified and
approved by the above agencies. They are
NOT ATEX compliant.
*Note: See page 18 for Special
Conditions For Safe Use.
s1fmdl1sm-REV0509
Performance Curve, S1F Metallic Design Level 1
MODEL S1F Metallic Performance Curve
5(00)
100
6
25(00)
80
80 P
SI (5
HEAD
5
4
3
10(17)
PSI
15(00)
(6.8
Bar
20(34)
)
60
60 PS
ar)
I (4.0
40
30(51)
.44 B
35(00)
40(68)
8 Bar
I (2.72
Bar)
2
20 PSI (1.3
6 Bar) Air In
1
0
0
0
30
25
20
15
10
5
9.1
7.6
6
4.5
3
1.5
)
40 PS
20
METERS
100
NPSHR
PSI
7
FEET
BAR
Performance based on the following: elastomer fitted pump, flooded suction, water at ambient conditions.
The use of other materials and varying hydraulic conditions may result in deviations in excess of 5%.
5
let Pressure
10
15
20
25
30
35
40
45
50
U.S. Gallons per minute
0
20
40
60
80
100
120
140
160
180
Liters per minute
CAPACITY
s1fmdl1sm-REV0509
Dimensions: S1F Metallic
Dimensions in Inches
Dimensional Tolerance: ±1/8"
Discharge Port
1" NPT
Suction Port
1" NPT
Pump Shown
With 530-028-550
Integral Muffler
Both Suction And
Discharge Ports Are
Available With
1" BSP Tapered Connection
Integral Muffler
1" NPT Exhaust Port
For Optional Muffler
Styles Or Piping Exhaust
Air In Submerged
Applications.
Air Inlet
1/2" NPT
s1fmdl1sm-REV0509
Dimension
A
Encapsulated
Muffler
Pulse Output
Kit
10 3/8
B
C
D
E
F
Aluminum
11 27/32
1 3/32
5/16
6 7/32
12 23/32
Stainless
Steel
11 31/32
1 7/32
7/16
6 11/32 12 27/32
10 3/8
Mesh
Muffler
13
Sound
Dampening
Muffler
13
Metal
Muffler
12 1/2
Metric Dimensions: S1F Metallic
Dimensions in Millimeters
Dimensional Tolerance: ± 3mm
Discharge Port
1" NPT
Suction Port
1" NPT
Integral Muffler
1" NPT Exhaust Port
For Optional Muffler
Styles Or Piping Exhaust
Air In Submerged
Applications
Air Inlet
1/2" NPT
s1fmdl1sm-REV0509
Pump Shown
With 530-028-550
Integral Muffler
Both Suction And
Discharge Ports Are
Available With
1" BSP Tapered Connection
Dimension
A
Encapsulated
Muffler
Pulse Output
Kit
264
B
C
D
E
F
Aluminum
301
28
8
158
323
Stainless
Steel
304
31
11
161
326
264
Mesh
Muffler
330
Sound
Dampening
Muffler
330
Metal
Muffler
319
PRINCIPLE OF PUMP OPERATION
This ball type check valve pump
is powered by compressed air and is
a 1:1 ratio design. The inner side of
one diaphragm chamber is alternately
pressurized while simultaneously
exhausting the other inner chamber.
This causes the diaphragms, which
are connected by a common rod
secured by plates to the centers of the
diaphragms, to move in a reciprocating
action. (As one diaphragm performs the
discharge stroke the other diaphragm is
pulled to perform the suction stroke in
the opposite chamber.) Air pressure is
applied over the entire inner surface of
the diaphragm while liquid is discharged
from the opposite side of the diaphragm.
The diaphragm operates in a balanced
condition during the discharge stroke
which allows the pump to be operated
at discharge heads over 200 feet (61
meters) of water.
For maximum diaphragm life, keep
the pump as close to the liquid being
pumped as possible. Positive suction
head in excess of 10 feet of liquid
(3.048 meters) may require a back
pressure regulating device to maximize
diaphragm life.
Alternate pressurizing and
exhausting of the diaphragm chamber
is performed by an externally mounted,
pilot operated, four way spool type
air distribution valve. When the spool
shifts to one end of the valve body, inlet
pressure is applied to one diaphragm
chamber and the other diaphragm
chamber exhausts. When the spool
shifts to the opposite end of the valve
body, the pressure to the chambers
s1fmdl1sm-REV0509
is reversed. The air distribution valve
spool is moved by a internal pilot valve
which alternately pressurizes one end
of the air distribution valve spool while
exhausting the other end. The pilot valve
is shifted at each end of the diaphragm
stroke when a actuator plunger is
contacted by the diaphragm plate. This
actuator plunger then pushes the end
of the pilot valve spool into position to
activate the air distribution valve.
The chambers are connected with
manifolds with a suction and discharge
check valve for each chamber,
maintaining flow in one direction through
the pump.
INSTALLATION AND START-UP
Locate the pump as close to the
product being pumped as possible.
Keep the suction line length and number
of fittings to a minimum. Do not reduce
the suction line diameter.
For installations of rigid piping,
short sections of flexible hose should
be installed between the pump and
the piping. The flexible hose reduces
vibration and strain to the pumping
system. A Warren Rupp Tranquilizer®
surge suppressor is recommended to
further reduce pulsation in flow.
AIR SUPPLY
Air supply pressure cannot exceed
125 psi (8.6 bar). Connect the pump
air inlet to an air supply of sufficient
capacity and pressure required for
desired performance. When the air
supply line is solid piping, use a short
length of flexible hose not less than ½"
(13mm) in diameter between the pump
and the piping to reduce strain to the
piping. The weight of the air supply line,
regulators and filters must be supported
by some means other than the air
inlet cap. Failure to provide support
for the piping may result in damage
to the pump. A pressure regulating
valve should be installed to insure
air supply pressure does not exceed
recommended limits.
AIR VALVE LUBRICATION
The air distribution valve and the pilot
valve are designed to operate WITHOUT
lubrication. This is the preferred mode
of operation. There may be instances
of personal preference or poor quality
air supplies when lubrication of the
compressed air supply is required.
The pump air system will operate with
properly lubricated compressed air
supply. Proper lubrication requires the
use of an air line lubricator (available
from Warren Rupp) set to deliver one
drop of SAE 10 non-detergent oil for
every 20 SCFM (9.4 liters/sec.) of air
the pump consumes at the point of
operation. Consult the pump’s published
Performance Curve to determine this.
AIR INLET AND PRIMING
To start the pump, open the air
valve approximately ½ to ¾ turn. After
the pump primes, the air valve can be
opened to increase air flow as desired.
If opening the valve increases cycling
rate, but does not increase the rate of
flow, cavitation has occurred. The valve
should be closed slightly to obtain the
most efficient air flow to pump flow
ratio.
BETWEEN USES
When the pump is used for materials
that tend to settle out or solidify when
not in motion, the pump should be
flushed after each use to prevent
damage. (Product remaining in the
pump between uses could dry out or
settle out. This could cause problems
with the diaphragms and check valves
at restart.) In freezing temperatures
the pump must be completely drained
between uses in all cases.
AIR LINE MOISTURE
Water in the compressed air supply
can create problems such as icing or
freezing of the exhaust air, causing
the pump to cycle erratically or stop
operating. Water in the air supply can
be reduced by using a point-of-use
air dryer to supplement the user’s air
drying equipment. This device removes
water from the compressed air supply
and alleviates the icing or freezing
problems.
TYPICAL INSTALLATION GUIDE
1
1 TA1 or TA25 Tranquilizer
2 020-050-000 Filter/Regulator
3 020-050-001 Lubricator
4 Air Dryer
Air Inlet
Line
CAUTION
The air exhaust should be
piped to an area for safe
disposition of the product
being pumped, in the event
of a diaphragm failure.
2
s1fmdl1sm-REV0509
TROUBLESHOOTING
Possible Symptoms:
• Pump will not cycle.
• Pump cycles, but produces no flow.
• Pump cycles, but flow rate is
unsatisfactory.
• Pump cycle seems unbalanced.
• Pump cycle seems to produce
excessive vibration.
What to Check: Excessive suction lift
in system.
Corrective Action: For lifts exceeding
20 feet (6 meters), filling the pumping
chambers with liquid will prime the
pump in most cases.
What to Check: Excessive flooded
suction in system.
Corrective Action: For flooded
conditions exceeding 10 feet (3
meters) of liquid, install a back pressure
device.
What to Check: System head exceeds
air supply pressure.
Corrective Action: Increase the
inlet air pressure to the pump. Most
diaphragm pumps are designed for 1:1
pressure ratio at zero flow.
What to Check: Air supply pressure or
volume exceeds system head.
Corrective Action: Decrease inlet
air pressure and volume to the
pump as calculated on the published
PERFORMANCE CURVE. Pump is
cavitating the fluid by fast cycling.
s1fmdl1sm-REV0509
What to Check: Undersized suction
line.
Corrective Action: Meet or exceed
pump connection recommendations
shown on the DIMENSIONAL
DRAWING.
W h a t t o C h e ck : R e s t r i c t e d o r
undersized air line.
Corrective Action: Install a larger
air line and connection. Refer to air
inlet recommendations shown in your
pump’s SERVICE MANUAL.
What to Check: Check ESADS+Plus,
t h e E x t e r n a l l y S e r v i c e a bl e A i r
Distribution System of the pump.
Corrective Action: Disassemble and
inspect the main air distribution valve,
pilot valve and pilot valve actuators.
Refer to the parts drawing and air valve
section of the SERVICE MANUAL.
Check for clogged discharge or closed
valve before reassembly.
What to Check: Rigid pipe connections
to pump.
Corrective Action: Install flexible
connectors and a Warren Rupp
Tranquilizer® surge suppressor.
What to Check: Blocked air exhaust
muffler.
Corrective Action: Remove muffler
screen, clean or de-ice and reinstall.
Refer to the Air Exhaust section of your
pump SERVICE MANUAL.
What to Check: Pumped fluid in air
exhaust muffler.
Corrective Action: Disassemble
pump chambers. Inspect for diaphragm
rupture or loose diaphragm plate
assembly. Refer to the Diaphragm
Replacement section of your pump
SERVICE MANUAL.
What to Check: Suction side air
leakage or air in product.
Corrective Action: Visually inspect
all suction side gaskets and pipe
connections.
What to Check: Obstructed check
valve.
Corrective Action: Disassemble the
wet end of the pump and manually
dislodge obstruction in the check valve
pocket. Refer to the Check Valve section
of the pump SERVICE MANUAL for
disassembly instructions.
What to Check: Worn or misaligned
check valve or check valve seat.
Corrective Action: Inspect check
valves and seats for wear and proper
seating. Replace if necessary. Refer
to Check Valve section of the pump
SERVICE MANUAL for disassembly
instructions.
What to Check: Blocked suction line.
Corrective Action: Remove or flush
obstruction. Check and clear all suction
screens and strainers.
What to Check: Blocked discharge
line.
C o r r e c t i v e A c t i o n : C h e ck fo r
obstruction or closed discharge line
valves.
What to Check: Blocked pumping
chamber.
Corrective Action: Disassemble and
inspect the wetted chambers of the
pump. Remove or flush any obstructions.
Refer to the pump SERVICE MANUAL
for disassembly instructions.
What to Check: Entrained air or
vapor lock in one or both pumping
chambers.
Corrective Action: Purge chambers
through tapped chamber vent plugs.
PURGING THE CHAMBERS OF AIR
CAN BE DANGEROUS! Contact the
Warren Rupp Technical Services Group
before performing this procedure. Any
model with top-ported discharge will
reduce or eliminate problems with
entrained air.
If your pump continues to perform
below your expectations, contact your
local Warren Rupp Distributor or factory
Technical Services Group for a service
evaluation.
WARRANTY
Refer to the enclosed Warren Rupp
Warranty Certificate.
Recycling
Many components of SANDPIPER®
Metallic AODD pumps are made of
recyclable materials (see chart on
page 10 for material specifications).
We encourage pump users to recycle
worn out parts and pumps whenever
possible, after any hazardous pumped
fluids are thoroughly flushed.
IMPORTANT SAFETY
INFORMATION
IMPORTANT
Read these safety warnings
and instructions in this
manual completely, before
installation and start-up
of the pump. It is the responsibility of the
purchaser to retain this manual for reference.
Failure to comply with the recommendations
stated in this manual will damage the pump,
and void factory warranty.
WARNING
Take action to prevent static
sparking. Fire or explosion
can result, especially when
handling flammable liquids.
The pump, piping, valves,
containers or other miscellaneous equipment
must be grounded. (See page 28)
WARNING
This pump is pressurized
internally with air pressure
during operation. Always
make certain that all bolting
is in good condition and
that all of the correct
bolting is reinstalled during assembly.
CAUTION
Before pump operation,
inspect all gasketed
fasteners for looseness
caused by gasket creep. Retorque loose fasteners to
prevent leakage. Follow recommended torques
stated in this manual.
WARNING
When used for toxic or
aggressive fluids, the pump
should always be flushed
clean prior to disassembly.
WARNING
WARNING
Before maintenance
or repair, shut off the
compressed air line,
bleed the pressure, and
disconnect the air line from
the pump. The discharge line may be pressurized
and must be bled of its pressure.
I M2 c T5
II 2GD T5
CE
s1fmdl1sm-REV0509
Pump complies with EN809 Pumping
Directive, Directive 98/37/EC Safety of
Machinery, and Directive 94/9/EC, EN13463-1
Equipment for use in Potentially Explosive
Environments. For reference to the directive
c e r t i f i c a t e s v i s i t : w w w. wa r r e n r u p p. c o m .
The Technical File No. AX1 is stored at
KEMA, Notified Body 0344, under Document
#203040000.
WARNING
In the event of diaphragm
rupture, pumped material
may enter the air end of the
pump, and be discharged
into the atmosphere. If
pumping a product which is hazardous or toxic,
the air exhaust must be piped to an appropriate
area for safe disposition.
Before doing any
maintenance on the pump,
be certain all pressure is
completely vented from the
pump, suction, discharge,
piping, and all other openings and connections.
Be certain the air supply is locked out or made
non-operational, so that it cannot be started
while work is being done on the pump. Be certain
that approved eye protection and protective
clothing are worn all times in the vicinity of the
pump. Failure to follow these recommendations
may result in serious injury or death.
WARNING
Airborne particles and
loud noise hazards.
Wear ear and eye
protection.
Material Codes
The Last 3 Digits of Part Number
000
010
012
015
020
025
080
100
110
111
112
113
114
115
117
120
123
148
149
150
151
152
154
155
156
157
158
159
162
165
166
170
175
Assembly, sub-assembly;
and some purchased items
Cast Iron
Powered Metal
Ductile Iron
Ferritic Malleable Iron
Music Wire
Carbon Steel, AISI B-1112
Alloy 20
Alloy Type 316 Stainless Steel
(Electro Polished)
Alloy C
(Hand Polished)
303 Stainless Steel
302/304 Stainless Steel
440-C Stainless Steel (Martensitic)
416 Stainless Steel
(Wrought Martensitic)
410 Stainless Steel
(Wrought Martensitic)
Hardcoat Anodized Aluminum
2024-T4 Aluminum
6061-T6 Aluminum
6063-T6 Aluminum
2024-T4 Aluminum (2023-T351)
Almag 35 Aluminum
356-T6 Aluminum
356-T6 Aluminum
Die Cast Aluminum Alloy #380
Aluminum Alloy SR-319
Anodized Aluminum
Brass, Yellow, Screw Machine Stock
Cast Bronze, 85-5-5-5
Bronze, SAE 660
Bronze, Bearing Type,
Oil Impregnated
Die Cast Zinc
s1fmdl1sm-REV0509
180
305
306
307
308
309
310
330
331
332
333
335
336
337
340
342
353
354
355
356
357
358
359
360
361
363
364
365
366
368
370
371
374
375
Copper Alloy
Carbon Steel, Black Epoxy Coated
Carbon Steel, Black PTFE Coated
Aluminum, Black Epoxy Coated
Stainless Steel, Black PTFE Coated
Aluminum, Black PTFE Coated
PVDF Coated
Zinc Plated Steel
Chrome Plated Steel
Aluminum, Electroless Nickel Plated
Carbon Steel, Electroless
Nickel Plated
Galvanized Steel
Zinc Plated Yellow Brass
Silver Plated Steel
Nickel Plated
Filled Nylon
Geolast; Color: Black
Injection Molded #203-40 SantopreneDuro 40D +/-5; Color: RED
Thermal Plastic
Hytrel
Injection Molded Polyurethane
Urethane Rubber
(Some Applications) (Compression Mold)
Urethane Rubber
Nitrile Rubber. Color coded: RED
FDA Accepted Nitrile
FKM (Fluorocarbon).
Color coded: YELLOW
E.P.D.M. Rubber. Color coded: BLUE
Neoprene Rubber.
Color coded: GREEN
Food Grade Nitrile
Food Grade EPDM
Butyl Rubber. Color coded: BROWN
Philthane (Tuftane)
Carboxylated Nitrile
Fluorinated Nitrile
378
379
405
408
425
426
440
465
500
501
502
503
505
506
520
521
540
541
542
544
550
551
552
553
555
556
557
558
559
570
580
590
591
592
600
601
602
603
High Density Polypropylene
Conductive Nitrile
Cellulose Fibre
Cork and Neoprene
Compressed Fibre
Blue Gard
Vegetable Fibre
Fibre
Delrin 500
Delrin 570
Conductive Acetal, ESD-800
Conductive Acetal, Glass-Filled
Acrylic Resin Plastic
Delrin 150
Injection Molded PVDF Natural color
Conductive PVDF
Nylon
Nylon
Nylon
Nylon Injection Molded
Polyethylene
Glass Filled Polypropylene
Unfilled Polypropylene
Unfilled Polypropylene
Polyvinyl Chloride
Black Vinyl
Conductive Polypropylene
Conductive HDPE
Glass-Filled Conductive Polypropylene
Rulon II
Ryton
Valox
Nylatron G-S
Nylatron NSB
PTFE (virgin material)
Tetrafluorocarbon (TFE)
PTFE (Bronze and moly filled)
Filled PTFE
Blue Gylon
604
606
607
608
610
611
632
633
634
635
637
638
639
643
644
650
654
656
661
PTFE
PTFE
Envelon
Conductive PTFE
PTFE Integral Silicon
PTFE Integral FKM
Neoprene/Hytrel
FKM (Fluorocarbon)/PTFE
EPDM/PTFE
Neoprene/PTFE
PTFE, FKM (Fluorocarbon)/PTFE
PTFE, Hytrel/PTFE
Nitrile/TFE
Santoprene/EPDM
Santoprene/PTFE
Bonded Santoprene and PTFE
Santoprene Diaphragm, PTFE Overlay
Balls and seals
Santoprene Diaphragm and
Check Balls/EPDM Seats
EPDM/Santoprene
Delrin and Hytrel are registered tradenames
of E.I. DuPont.
Gylon is a registered tradename of Garlock, Inc.
Nylatron is a registered tradename of
Polymer Corp.
Santoprene is a registered tradename of
Monsanto Corp.
Rulon II is a registered tradename of
Dixion Industries Corp.
Ryton is a registered tradename of
Phillips Chemical Co.
Valox is a registered tradename of
General Electric Co.
Warren Rupp, SANDPIPER, PortaPump,
Tranquilizers and SludgeMaser are registered
tradenames of IDEX AODD, Inc
s1fmdl1sm-REV0509
Composite Repair Parts Drawing
AVAILABLE SERVICE AND CONVERSION KITS
476-228-000
AIR END KIT (Aluminum Center)
Seals, O-ring, Gaskets, Retaining Rings, Air Valve
Sleeve and Spool Set, and Pilot Valve Assembly.
476-201-000
AIR END KIT (Air Valve with Stroke Indicator Pin, Aluminum Center)
Seals, O-ring, Gaskets, Retaining Rings, Air Valve
Sleeve and Spool Set, and Pilot Valve Assembly.
476-194-354
WET END KIT
Nitrile Diaphragms, Balls, and Polyethylene Seats.
476-194-365
WET END KIT
Neoprene Diaphragms, Balls, and Polyethylene Seats.
476-194-633
WET END KIT
FKM Diaphragms, PTFE Overlay, PTFE Balls and Seats.
476-194-654
476-194-661
476-194-659
18
17
31
25
20
7
21
WET END KIT
Neoprene Diaphragms, PTFE Overlay
Balls and Seats.
9
26
WET END KIT
Santoprene Diaphragms, PTFE Overlay,
PTFE Balls, PTFE Seats.
30
2
3
28
16
WET END KIT
EPDM Diaphragms, Santoprene Balls
and Polyethylene Seats.
WETTED END KIT
One-PIece Bonded PTFE/Nitrile Diaphragm,
PTFE Balls, PTFE Seats.
11
4
WET END KIT
Santoprene Diaphragms, Balls and Polyethylene Seats.
476-194-360
476-194-635
8
1
5
29
27
13
6
12
10
23
32
14
OPTIONAL MUFFLER
15
14
HARDWARE KITS
475-212-330
Zinc Plated Capscrews, Washers,
and Hex Nuts.
475-212-115
Stainless Steel Capscrews, Washers,
and Hex Nuts.
24
2
23
29
22
OPTIONAL OVERLAY
19
29
30
22
9
OPTIONAL METALLIC SEAT
s1fmdl1sm-REV0509
Composite Repair Parts List
ITEM
1
PART NUMBER
DESCRIPTION
031-179-000
031-146-000
031-147-000
031-183-000
031-183-001
Air Valve Assembly (Cast Iron Centers Only)
Air Valve Assembly (Stroke Indicator)
Air Valve Assembly (Stroke Indicator)
Air Valve Assembly
Air Valve Assembly
(W/Stainless Steel Hardware)
Air Valve Assembly
(W/ Aluminum centers only)
Air Valve Assembly
(W/ Stainless Steel Hardware only)
Ball, Check
Ball, Check
Ball, Check
Ball, Check
Bushing
Pilot Valve Assembly
(Cast Iron Centers Only)
Intermediate
Intermediate
Bumper
Bushing
Cap, Air Inlet Assembly
Cap, Air Inlet Assembly
Capscrew, Hex Hd 5/16-18 X 1.00
Capscrew, Hex Soc 3/8-16 X 2.50
(Stroke Indicator option only)
Capscrew, Hex Soc 3/8-16 X 2.50
(Stroke Indicator option only)
Capscrew, Hex HD 3/8-16 X 1.00
Capscrew, Hex HD 3/8-16 X 1.00
Chamber, Outer
Chamber, Outer
Chamber, Outer
Diaphragm
Diaphragm
Diaphragm
Diaphragm
Diaphragm
Diaphragm, One-Piece Bonded
Diaphragm, Overlay
Gasket, Air Valve
Gasket, Pilot Valve
Gasket, Air Inlet Cap
Manifold, Suction
031-173-000
031-173-001
2
3
4
5
6
7
8
9
10
11
12
050-028-354
050-028-360
050-028-365
050-028-600
070-012-170
095-110-000
095-110-558
114-025-157
114-025-010
132-019-360
135-036-506
165-120-157
165-120-010
170-044-115
170-044-330
170-045-115
170-045-330
170-069-115
170-069-330
171-053-115
171-053-330
13
14
15
16
17
18
19
170-006-115
170-006-330
196-173-156/157
196-173-010
196-173-110
286-008-354
286-008-360
286-008-363
286-008-364
286-008-365
286-112-000
286-015-604
360-093-360
360-114-360
360-104-379
518-175-156
s1fmdl1sm-REV0509
QTY
ITEM
1
1
1
1
1
20
1
1
4
4
4
4
2
1
1
21
22
23
1
1
2
2
1
1
16
16
16
16
4
4
4
24
25
26
27
28
29
4
30
4
4
2
2
2
2
2
2
2
2
2
2
1
1
1
1
31
32
PART NUMBER
DESCRIPTION
518-175-156E
518-175-010
518-175-010E
518-175-110
518-175-110E
518-176-156
518-176-156E
518-176-010
518-176-010E
518-176-110
518-176-110E
560-001-360
560-091-360
560-091-363
560-091-364
560-091-365
560-091-611
612-022-330
612-218-330
Manifold, Suction 1" BSP Tapered
Manifold, Suction
Manifold, Suction
Manifold, Discharge
Manifold, Discharge 1" BSP Tapered
Manifold, Discharge
Manifold, Discharge
O-Ring
Seal (Check Valve) (See item 29)
Plate, Inner Diaphragm
Plate, Inner Diaphragm
(use with One-Piece Bonded)
Plate, Outer Diaphragm Assembly
Pin, Actuator
Ring, Retaining
Rod, Diaphragm
Seal, U-Cup
Seat, Check Ball
Seat, Check Ball (seals required see item 22)
Seat, Check Ball
Lock Washer, 5/16
Lock Washer, 5/16
Flat Washer, 5/16
Flat Washer, 5/16
Muffler, Metal
612-108-157
612-101-082
612-101-110
620-022-115
675-042-115
685-060-120
720-010-375
722-098-550
722-098-080
722-098-110
722-098-150
722-098-600
900-004-330
900-004-115
901-038-330
901-038-115
530-033-000
QTY
1
1
1
1
1
1
1
1
1
1
1
2
8
8
8
8
8
2
2
2
2
2
2
2
1
2
4
4
4
4
4
16
16
4
4
1
Parts not shown used with Raised Face Flange Porting Option
170-044-330
326-050-080
334-112-110
538-035-110
545-004-330
900-004-330
901-009-330
Hex Cap Screw
Mounting Bracket
1" Raised Face, 150# ANSI Flange
Pipe Nipple 1" NPT x 1½"
Hex Nut
Lock Washer
Flat Washer
4
2
2
2
4
4
8
ATEX Compliant
Air Valve Servicing, Assembly Drawing & Parts List (Use With Aluminum Centers Only)
1-J
1-F
1-E
1-D
1-D
1-H
1-C
1-G
1-B
1-B
**AIR VALVE ASSEMBLY PARTS LIST
Item
Part Number
Description
1
031-173-000
Air Valve Assembly
1-A
095-109-157
Body, Air Valve
1-B
031-139-000
Sleeve and Spool Set
1-C
132-029-357
Bumper
1-D
560-020-360
O-Ring
1-E
165-127-157
Cap, End
1-F
170-032-330
Hex Head Capscrew 1/4-20 x .75
1-G
530-028-550
Muffler
1-H
165-096-551
Muffler Cap
1-J
706-026-330
Machine Screw
**AIR VALVE ASSEMBLY PARTS LIST
1
031-173-001
Air Valve Assembly
Consists of all components above except:
1-F
170-032-115
1-J
706-026-115
Machine Screw
1-E
1-A
Qty
1
1
1
2
10
2
8
1
1
4
1
8
4
1-C
1-D
**Note: Pumps equipped with these Valve Assemblies are not ATEX compliant.
1-F
AIR DISTRIBUTION VALVE SERVICING
To service the air valve first shut off the
compressed air, bleed pressure from the
pump, and disconnect the air supply line
from the pump.
Step #1: See COMPOSITE REPAIR PARTS
DRAWING.
Using a 9/16" wrench or socket, remove
the four hex capscrews (items 12). Remove
the air valve assembly from the pump.
Remove and inspect gasket (item 16)
for cracks or damage. Replace gasket if
needed.
Step #2: Disassembly of the air valve.
the eight hex capscrews (items 1-F) that
s1fmdl1sm-REV0509
fasten the end caps to the valve body.
Next remove the two end caps (items 1-E).
Inspect the two o-rings (items 1-D) on each
end cap for damage or wear. Replace the
o-rings as needed.
Remove the bumpers (items 1-C).
Inspect the bumpers for damage or wear.
Replace the bumpers as needed.
Remove the spool (part of item 1-B)
from the sleeve. Be careful not to scratch
or damage the outer diameter of the spool.
Wipe spool with a soft cloth and inspect for
scratches or wear.
Inspect the inner diameter of the sleeve
(part of item 1-B) for dirt, scratches, or other
contaminants. Remove the sleeve if needed
and replace with a new sleeve and spool
set (item 1-B).
Step #3: Reassembly of the air valve.
Install one bumper (item 1-C) and one
end cap (item 1-E), with two o-rings (items
1-D), and fasten with four hex capscrews
(items 1-F) to the valve body (item 1-A).
Remove the new sleeve an spool set
(item 1-B) from the plastic bag. Carefully
remove the spool from the sleeve. Install the
six o-rings (item 1-D) into the six grooves
on the sleeve. Apply a light coating of
grease to the o-rings before installing the
sleeve into the valve body (item 1-A), align
the slots in the sleeve with the slots in the
valve body. Insert the spool into the sleeve.
Be careful not to scratch or damage the
spool during installation. Carefully insert
the sleeve into the bumper and end cap
(with o-rings) and fasten with the remaining
hex capscrews.
Fasten the air valve assembly (item
1) and gasket to the pump. Connect the
compressed air line to the pump. The pump
is now ready for operation.
IMPORTANT
Read these instructions
c o m p l e t e l y, b e f o r e
installation and start-up.
It is the responsibility of
the purchaser to retain
this manual for reference. Failure to comply
with the recommendations stated in this
manual will damage the pump, and void
factory warranty.
Air Valve Servicing, Assembly Drawing & Parts List
1-F
1-E
1-D
1-D
1-C
AIR VALVE ASSEMBLY PARTS LIST (Use w/Aluminum center sections)
Item
Part Number
Description
Qty
1
031-183-000
Air Valve Assembly
1
1-A
095-109-157
Body, Air Valve
1
1-B
031-139-000
1
1-C
132-029-357
Bumper
2
1-D
560-020-360
O-Ring
10
1-E
165-127-157
Cap, End
2
1-F
170-032-330
8
1-B
1-B
1-E
AIR VALVE ASSEMBLY PARTS LIST
1
031-183-001
Air Valve Assembly
Consists of all components above except:
1-F
170-032-115
1
8
1-A
1-C
ATEX Compliant
1-D
1-F
AIR DISTRIBUTION VALVE SERVICING
compressed air, bleed pressure from the
pump, and disconnect the air supply line
from the pump.
DRAWING.
the four hex capscrews (items 12). Remove
the air valve assembly from the pump.
needed.
the eight hex capscrews (items 1-F) that
s1fmdl1sm-REV0509
fasten the end caps to the valve body.
Next remove the two end caps (items 1-E).
Inspect the two o-rings (items 1-D) on each
end cap for damage or wear. Replace the
o-rings as needed.
Remove the bumpers (items 1-C).
Inspect the bumpers for damage or wear.
Replace the bumpers as needed.
Remove the spool (part of item 1-B)
scratches or wear.
Inspect the inner diameter of
the sleeve (part of item 1-B) for dirt,
scratches, or other contaminants. Remove
the sleeve if needed and replace with
a new sleeve and spool set (item 1-B).
Install one bumper (item 1-C) and one
end cap (item 1-E), with two o-rings (items
1-D), and fasten with four hex capscrews
(items 1-F) to the valve body (item 1-A).
Remove the new sleeve an spool set
(item 1-B) from the plastic bag. Carefully
six o-rings (item 1-D) into the six grooves
sleeve into the valve body (item 1-A), align
spool during installation. Carefully insert
the sleeve into the bumper and end cap
(with o-rings) and fasten with the remaining
hex capscrews.
Fasten the air valve assembly (item
1) and gasket to the pump. Connect the
compressed air line to the pump. The pump
is now ready for operation.
IMPORTANT
this manual for reference. Failure to
comply with the recommendations stated
in this manual will damage the pump, and
void factory warranty.
Air Valve Assembly Drawing, Parts List
(Use With Cast Iron Centers Only)
1-F
1-D
Air Valve Assembly Parts List
1-D
1-C
1-E
1-B
1-B
Item
1
1-A
1-B
1-C
1-D
1-E
1-F
Part Number
031-179-000
095-109-110
031-139-000
132-029-357
560-020-360
165-127-110
170-032-115
*
Description
Gas Valve Assembly
Valve Body
Bumper
O-Ring
Cap, End
Capscrew
Qty
1
1
1
2
10
2
8
1-A
1-C
1-D
*
Note: cannot be used with
integral muffler Option 0.
ATEX Compliant
1-F
1-E
AIR DISTRIBUTION VALVE WITH
STROKE INDICATOR OPTION
SERVICING
compressed air supply, bleed the pressure
from the pump, and disconnect the air
supply line from the pump.
DRAWING.
Using a 5/16" Allen wrench, remove the
four hex socket capscrews (item 12) and four
flat washers (item 39). Remove the air valve
assembly from the pump.
needed.
s1fmdl1sm-REV0509
To access the inter nal air valve
components first remove the two retaining
rings (item 1-H) from each end of the air
valve assembly using clip ring pliers.
Next remove the two end caps (item
1-E). Inspect the o-ring (items 1-G) for cuts
or wear. Replace the o-rings if necessary.
Remove the spool (part of item 1-A)
scratches or wear.
(part of item 1-A) for dirt, scratches, or other
contaminants. Remove the sleeve if needed
and replace with a new sleeve and spool
set (item 1-A).
Install one end cap (item 1-E) with
o-ring (item 1-G) into one end of the air
valve body (item 1-B). Install one retaining
ring (item 1-H), into the groove on the same
end.
Remove the new sleeve and spool set
(item 1-A) from the plastic bag. Carefully
six o-rings (item 1-G) into the six grooves on
the sleeve. Apply a light coating of grease to
the o-rings before installing the sleeve into
the valve body (item 1-B). Align the slots in
the sleeve with the slots in the valve body.
Insert the spool into the sleeve. Be careful
not to scratch or damage the spool during
installation. Push the spool in until it touches
the bumper on the opposite end.
Install the remaining end cap with
o-rings and retaining ring.
Fa s t e n t h e a i r va l ve a s s e m bl y
(item 1) and gasket (item 19) to the pump.
Connect the compressed air line to the
pump. Remove the safety clip. The pump is
now ready for operation.
IMPORTANT
Air Valve with Stroke Indicator Assembly Drawing, Parts List
AIR VALVE ASSEMBLY PARTS LIST
Item
1
1-A
1-B
1-C
1-D
1-E
1-F
1-G
1-H
1-J
1-K
1-M
ATEX Compliant
A I R D I S T R I B U T I O N VA LV E W I T H
S T R O K E I N D I C AT O R O P T I O N
SERVICING
compressed air supply, bleed the pressure
from the pump, and disconnect the air
supply line from the pump.
DRAWING.
Using a 5/16" Allen wrench, remove the
four hex socket capscrews (item 12) and four
flat washers (item 39). Remove the air valve
assembly from the pump.
needed.
To access the inter nal air valve
s1fmdl1sm-REV0509
components first remove the two retaining
rings (item 1-H) from each end of the air
valve assembly using clip ring pliers.
Next remove the two end caps (item
1-E). Inspect the o-ring (items 1-G) and
1-M) for cuts or wear. Replace the o-rings
if necessary.
Remove the two bumpers (item
1-C). Inspect the bumpers for cut, wear or
abrasion. Replace if necessary.
Remove the spool (part of item 1-A)
scratches or wear.
(part of item 1-A) for dirt, scratches, or
other contaminants. Remove the sleeve if
needed and replace with a new sleeve and
spool set(item 1-A).
Part Number
031-146-000
031-143-000
095-094-559
132-029-552
165-096-559
165-098-147
530-028-550
560-020-360
675-044-115
710-015-115
210-008-330
560-029-360
Description
Air Valve Assembly
Body, Air Valve
Bumper
Cap, Muffler
Cap, End
Muffler
O-Ring
Ring, Retaining
Screw, Self Tapping
Clip, Safety
O-Ring
Qty
1
1
1
2
1
2
1
8
2
4
1
2
For Pumps with Alternate Mesh, Sound Dampening Mufflers
or Piped Exhaust:
1
031-147-000
Air Valve Assembly
1
(includes all items on 031-146-000 minus 1-D, 1-F, & 1-J).
Install one bumper (item 1-C) and
one end cap (item 1-E) with o-rings
(item 1-G and 1-M) into one end of the air
valve body (item 1-B). Install one retaining
ring (item 1-H), into the groove on the same
end. Insert the safety clip (item 1-K) through
the smaller unthreaded hole in the endcap.
Remove the new sleeve and spool set
(item 1-A) from the plastic bag. Carefully
six o-rings (item 1-G) into the six grooves
sleeve into the valve body (item 1-B). Align
spool during installation. Push the spool in
until the pin touches the safety clip on the
opposite end.
Install the remaining bumper, end cap
with o-rings and retaining ring.
Fa s t e n t h e a i r va l ve a s s e m bl y
(item 1) and gasket (item 19) to the pump.
Connect the compressed air line to the
pump. Remove the safety clip. The pump is
now ready for operation.
IMPORTANT
Solenoid Shifted Air Valve Drawing
36
SOLENOID SHIFTED AIR VALVE PARTS LIST
(Includes all items used on Composite Repair Parts List except as shown)
ITEM
33
34
35
36
37
PART NUMBER
893-097-000
219-001-000
219-004-000
219-002-000
219-003-000
241-001-000
241-003-000
170-045-330
618-050-150
DESCRIPTION
Solenoid Valve, NEMA4
Solenoid Coil, 24VDC
Solenoid Coil, 24VAC/12VDC
Solenoid Coil, 120VAC
Solenoid Coil, 240VAC
Connector, conduit
Conduit Connector with
Suppression Diode (DC Only)
Capscrew, Hex HD 5/16-18 x 1.25
Plug
QTY
1
1
1
1
1
1
1
37
33
35
4
2
34
IEC EEX m T4
34
For Explosion Proof Solenoid Coils used in North America and
outside the European Union.
219-009-001
Solenoid Coil, 120VAC 60 HZ
219-009-002
219-009-003
219-009-004
219-009-005
219-009-006
Note: Item 35 (Conduit Connector) is not required
37
1
1
1
1
1
1
33
II 2G EEx m c T5
II 2D c IP65 T100°C
*
34
For Explosion Proof Solenoid Coils used in the European Union
219-011-001
Solenoid Coil, 12 VDC, 3.3W / 0, 531A...0, 014A
219-011-002
Solenoid Coil, 24 VDC, 3.3W / 0, 531A...0, 014A
219-011-003
Solenoid Coil, 110/120 VAC, 3.4W / 0, 212A...0, 015A
219-011-004
Solenoid Coil, 220/240 VAC, 3.4W / 0, 212A...0, 015A
Note: Item 35 (Conduit Connector) is not required
1
1
1
1
*Special Conditions For Safe Use
A fuse corresponding to its rated current (max. 3*Irat according IEC 60127-2-1) or a motor protecting switch with short-circuit and thermal instantaneous tripping (set to rated current) shall be connected in
series to each solenoid as short circuit protection. For very low rated currents of the solenoid the fuse of lowest current value according to the indicated IEC standard will be sufficient. The fuse may be
accommodated in the associated supply unit or shall be separately arranged. The rated voltage to the fuse shall be equal to or greater than the stated rated voltage of the magnet coil. The breakage
capacity of the fuse-link shall be as high as or higher than the maximum expected short circuit current at the location of the installation (usually 1500 A). A maximum permissible ripple of 20% is valid for
all magnets of direct-current design.
s1fmdl1sm-REV0509
SOLENOID SHIFTED AIR
DISTRIBUTION VALVE OPTION
Warren Rupp’s solenoid shifted,
air distribution valve option utilizes
electrical signals to precisely control
your SANDPIPERs speed. The solenoid
coil is connected to a customer supplied control. Compressed air
provides the pumping power, while
electrical signals control pump speed
(pumping rate).
Solenoid Connector
Before wiring, remove
terminal block from
conduit connector.
Wiring
Diagram
3rd Terminal for
ground.
#2 Terminal Neutral
(Negative)
#1 Terminal
Power
(Positive)
OPERATION
The Solenoid Shifted SANDPIPER has a
solenoid operated, air distribution valve
in place of the standard SANDPIPERs
pilot operated, air distribution valve.
Where a pilot valve is normally utilized
to cycle the pump’s air distribution valve,
an electric solenoid is utilized. As the
solenoid is powered, one of the pump’s
air chambers is pressurized while the
other chamber is exhausted. When
electric power is turned off, the solenoid
shifts and the pressurized chamber is
exhausted while the other chamber is
pressurized. By alternately applying
and removing power to the solenoid,
the pump cycles much like a standard
SANDPIPER pump, with one exception.
This option provides a way to precisely
control and monitor pump speed.
BEFORE INSTALLATION
Before wiring the solenoid, make
certain it is compatible with your system
voltage.
s1fmdl1sm-REV0509
Diaphragm Service Drawing, Diaphragm Service Drawing,
with Overlay
Non-Overlay
One-Piece Bonded
* DiaphragmService
Drawing
14
*AVAILABLE FOR FIELD CONVERSION FROM OVERLAY
TO ONE-PIECE BONDED DIAPHRAGM KITS:
Kit:
2
2
475-250-000
286-112-000
612-218-330
s1fmdl1sm-REV0509
One-Piece Diaphragm
Inner Plates
DIAPHRAGM SERVICING
To service the diaphragms first shut
off the suction, then shut off the
discharge lines to the pump. Shut off the
compressed air supply, bleed the
pressure from the pump and disconnect
the air supply line from the pump. Drain
any remaining liquid from the pump.
Step #1: See the pump assembly
drawing and the diaphragm servicing
illustration.
Using a 1/2” wrench or socket,
remove the 16 capscrews (item 9) that
fasten the manifolds (items 19 & 20) to
the outer chambers (item 13).
Step #2: Removing outer
chambers.
Using a 1/2” wrench or socket,
remove the 16 capscrews (item 10), that
fasten the outer chambers (item 13),
diaphragms (item 14) and intermediate
(item 5) together.
Step #3: Removing the diaphragms and diaphragm plates.
Use a 7/8” wrench or six point
socket to remove the outer diaphragm
plate assemblies (item 24), diaphragms
(item 14) and inner diaphragm plates
(item 23) from the diaphragm rod
(item 27) by turning counterclockwise.
Inspect the diaphragm for cuts, punctures,
abrasive wear or chemical attack.
Replace the diaphragms if necessary.
DO NOT USE A WRENCH ON THE
DIAPHRAGM ROD. FLAWS ON THE
SURFACE MAY DAMAGE BEARINGS
AND SEALS.
s1fmdl1sm-REV0509
Step #4: Assembling the
diaphragm and diaphragm plates to the
diaphragm rod.
Push the threaded stud of one outer
diaphragm plate assembly through the
center of one diaphragm and through
one inner diaphragm plate. Install the
diaphragm with the natural bulge facing
away from the diaphragm rod and make
sure the radius on the inner diaphragm
plate is towards the diaphragm, as
indicated on the diaphragm servicing
illustration. Thread the assembly onto
the diaphragm rod, leaving loose.
Align one diaphragm with the
intermediate and install the outer
chamber to the pump using the 8
capscrews. Tighten the opposite
diaphragm plate until the holes in the
diaphragm align with the holes in the
intermediate. Then, install the other
outer chamber using the 8 capscrews.
Step #5: Installing the diaphragm
and rod assembly to the pump.
Make sure the bumper (item 6) is
installed over the diaphragm rod. Insert
rod into pump.
On the opposite side of the pump,
pull the diaphragm rod out as far as
possible. Make sure the second bumper
is installed over the diaphragm rod.
Push the threaded stud of the other
outer diaphragm plate assembly through
the center of the other diaphragm and
through the other inner diaphragm
plate. Make sure the radius on the inner
diaphragm plate is towards the
diaphragm. Thread the assembly onto
the diaphragm rod. Use a 7/8” wrench
or socket to hold one outer diaphragm
plate. Then, use a torque wrench to
tighten the other outer diaphragm plate
to the diaphragm rod to 500 in. lbs. (56.5
Newton meters).
OVERLAY DIAPHRAGM SERVICING
The overlay diaphragm (item 15) is
designed to fit over the exterior of the
standard diaphragm (item 14).
Follow the same procedures
described for the standard diaphragm for
removal and installation, except tighten
the outer diaphragm plate assembly,
diaphragms and inner diaphragm plate
to the diaphragm rod to 500 in. lbs.
(56.5 Newton meters).
Step #6: Reinstall the manifolds to the
pump using the 16 capscrews.
The pump is now ready to be
reinstalled, connected and returned to
operation.
One-Piece Bonded DIAPHRAGM
SERVICING (Bonded PTFE with
integral plate)
The one-piece bonded diaphragm
(item 14) has a threaded stud installed
in the integral plate at the factory. The
inner diaphragm plate has a through
hole instead of a threaded hole.
IMPORTANT
c o m p l e t e l y, b e fo r e
Place the inner plate over the
diaphragm stud and thread the first
diaphragm / inner plate onto the diaphragm rod only until the inner plate
contacts the rod. Do not tighten. A small
amount of grease may be applied between
the inner plate and the diaphragm to
facilitate assembly.
Insert the diaphragm / rod assembly into the pump and install the
outer chamber. Turn the pump over
and thread the second diaphragm /
inner plate onto the diaphragm rod.
Turn the diaphragm until the inner
plate contacts the rod and hand tighten
the assembly. Continue tightening
until the bolt holes align with the inner
chamber holes. DO NOT LEAVE THE
ASSEMBLY LOOSE.
Pilot Valve Servicing, Assembly Drawing & Parts List
PILOT VALVE ASSEMBLY PARTS LIST
ITEM
4
4-A
4-B
4-C
4-D
4-E
4-F
PART NUMBER
095-110-000
095-095-157
755-052-000
560-033-360
775-055-000
560-023-360
675-037-080
DESCRIPTION
Valve Body
Sleeve (With O-rings)
O-ring (Sleeve)
Spool (With O-rings)
O-ring (Spool)
Retaining Ring
QTY
1
1
1
6
1
3
1
FOR PUMPS WITH CAST IRON CENTER SECTION
ITEM
PART NUMBER
DESCRIPTION
4
095-110-558
4-A
095-095-558
Valve Body
(includes all other items used on 095-110-000)
PILOT VALVE SERVICING
To service the pilot valve first shut
off the compressed air supply, bleed
the pressure from the pump, and
disconnect the air supply line from the
pump.
STEP #1: See pump assembly
drawing.
Using a 1/2" wrench or socket,
remove the four capscrews (item 11).
Remove the air inlet cap (item 8) and
air inlet gasket (item 18). The pilot valve
assembly (item 4) can now be removed
for inspection and service.
s1fmdl1sm-REV0509
QTY
1
1
STEP #2: Disassembly of the pilot
valve.
Remove the pilot valve spool (item
4-D). Wipe clean and inspect spool and
o-rings for dirt, cuts or wear. Replace
the o-rings and spool if necessary.
Remove the retaining ring (item
4-F) from the end of the sleeve (item
4-B) and remove the sleeve from the
valve body (item 4-A). Wipe clean and
inspect sleeve and o-rings for dirt, cuts
or wear. Replace the o-rings and sleeve
if necessary.
STEP #3: Re-assembly of the pilot
valve.
Generously lubr icate outside
diameter of the sleeve and o-rings.
Then carefully insert sleeve into valve
body. Take CAUTION when inserting
sleeve, not to shear any o-rings. Install
retaining ring to sleeve. Generously
lubricate outside diameter of spool and
o-rings. Then carefully insert spool into
sleeve. Take CAUTION when inserting
spool, not to shear any o-rings. Use
BP-LS-EP-2 multipurpose grease, or
equivalent.
STEP #4: Re-install the pilot valve
assembly into the intermediate.
Be careful to align the ends of the
pilot valve stem between the plunger
pins when inserting the pilot valve into
the cavity of the intermediate.
Re-install the gasket, air inlet cap
and capscrews. Connect the air supply
to the pump. The pump is now ready
for operation.
ACTUATOR PLUNGER SERVICING
To service the actuator plunger first
shut off the compressed air supply,
bleed the pressure from the pump, and
disconnect the air supply line from
the pump.
Step #1: See PUMP ASSEMBLY
DRAWING.
Using a 1/2" wrench or socket,
remove the four capscrews (items 11).
Remove the air inlet cap (item 8) and
air inlet gasket (item 18). The pilot
valve assembly (item 4) can now be
removed.
Step #2: Inspect the actuator
plungers.
See ILLUSTRATION AT RIGHT.
The actuator plungers (items 25)
can be reached through the pilot valve
cavity in the intermediate assembly
(item 5).
Remove the plungers (item 25) from
the bushings (item 7) in each end of
the cavity. Inspect the installed o-ring
(items 21) for cuts and/or wear. Replace
the o-rings if necessary. Apply a light
coating of grease to each o-ring and
re-install the plungers in to the bushings.
Push the plungers in as far as they will
go.
To remove the bushings (item
7), first remove the retaining rings
(item 26) by using a flat screwdriver.
NOTE: It is recommended that new
retaining rings be installed.
Step #3: Re-install the pilot
valve assembly into the intermediate
assembly.
Be careful to align the ends of
the stem between the plungers when
inserting the stem of the pilot valve into
the cavity of the intermediate.
Re-install the gasket (item 18), air
inlet cap (item 8) and capscrews (item
11).
Connect the air supply to the pump.
The pump is now ready for operation.
IMPORTANT
c o m p l e t e l y, b e fo r e
ACTUATOR PLUNGER SERVICING
25
21
7
26
5
s1fmdl1sm-REV0509
CHECK VALVE SERVICING
Before servicing the check valve
components, first shut off the suction
line and then the discharge line to the
pump. Next, shut off the compressed
air supply, bleed air pressure from the
pump, and disconnect the air supply
line from the pump. Drain any remaining
fluid from the pump. The pump can now
be removed for service.
To a c c e s s t h e c h e c k va l ve
components, remove the manifold
(item 20 or item 19 not shown). Use a
1
/ 2 " wrench or socket to remove
the fasteners. Once the manifold is
removed, the check valve components
can be seen.
Inspect the check balls (items 2) for
wear, abrasion, or cuts on the spherical
surface. The check valve seats (item
29) should be inspected for cuts,
abrasive wear, or embedded material
on the surfaces of both the external
and internal chambers. The spherical
surface of the check balls must seat
flush to the surface of the check valve
seats for the pump to operate to
peak efficiency. Replace any worn or
damaged parts as necessary.
Re-assemble the check valve
components. The seat should fit into the
counter bore of the outer chamber.
The pump can now be reassembled,
reconnected and returned to
operation.
Check Valve Drawing
20
9
30
22
2
29
29
22
with Metallic Seats
with Non-Metallic
Seats
METALLIC SEATS
Two o-rings (item 22) are required
for metallic seats.
s1fmdl1sm-REV0509
Optional Muffler Configurations, Drawing
OPTION 0
*
530-028-550 Encapsulated Muffler uses (1)
Cap and (4) 710-015-115 Self Tapping Screw
to hold it in place.
OPTION 1
530-027-000 Sound Dampening Muffler
screws directly into the Air Valve body.
This muffler is equipped with a porous
plastic element.
*
Note: Cannot be used with Air Valve
Assembly 031-179-000 used with
cast iron centers.
OPTION 2
530-010-000 Mesh Muffler screws
directly into the Air Valve Body. This
muffler is equipped with a metal element.
OPTION 6
530-033-000 Metal Muffler screws
directly into the Air Body.
ATEX Compliant
Option 0
Option 1 and 2
Option 6
s1fmdl1sm-REV0509
PUMPING HAZARDOUS LIQUIDS
When a diaphragm fails, the pumped
liquid or fumes enter the air end of
the pump. Fumes are exhausted into
the surrounding environment. When
pumping hazardous or toxic materials,
the exhaust air must be piped to an
appropriate area for safe disposal. See
illustration #1 at right.
This pump can be submerged if
the pump materials of construction
are compatible with the liquid being
pumped. The air exhaust must be
piped above the liquid level. See
illustration #2 at right. Piping used for
the air exhaust must not be smaller
than 1" (2.54 cm) diameter. Reducing
the pipe size will restrict air flow and
reduce pump performance. When the
pumped product source is at a higher
level than the pump (flooded suction
condition), pipe the exhaust higher than
the product source to prevent siphoning
spills. See illustration #3 at right.
CONVERTING THE PUMP FOR
PIPING THE EXHAUST AIR
The following steps are necessary to
convert the pump to pipe the exhaust
air away from the pump.
Remove the muffler (item 31). The
air distribution valve (item 1) has 1" NPT
threads for piped exhaust.
IMPORTANT INSTALLATION
NOTE: The manufacturer recommends
installing a flexible conductive hose
or connection between the pump
and any rigid plumbing. This reduces
stresses on the molded threads of the
air exhaust port. Failure to do so may
result in damage to the air distribution
valve body.
Any piping or hose connected to
the pump’s air exhaust port must be
conductive and physically supported.
Failure to support these connections
could also result in damage to the air
distribution valve body.
1
CONVERTED EXHAUST ILLUSTRATION
PUMP INSTALLATION AREA
1" DIAMETER AIR
EXHAUST PIPING
MUFFLER
Illustration #1
MUFFLER
Air Valve
Assembly
LIQUID
LEVEL
1" DIAMETER AIR
EXHAUST PIPING
SUCTION
LINE
31
Illustration #2
MUFFLER
On ATEX compliant units the
pump comes equipped with
a standard metal muffler
LIQUID
LEVEL
Illustration #3
s1fmdl1sm-REV0509
SAFE AIR
EXHAUST
DISPOSAL
AREA
1" DIAMETER AIR
EXHAUST PIPING
SUCTION
LINE
Pulse Output Kit Drawing
PULSE OUTPUT KIT OPTION
This pump can be fitted with a Pulse Output Kit. This converts the mechanical
strokes of the pump to an electrical signal which interfaces with the RuppTech®
Stroke Counter/ Batch Controller or user control devices such as a PLC.
The Pulse Output Kits mount directly onto the Muffler Cap on the Air Distribution
Valve Assembly or onto the air valve and senses each stroke of the main spool.
Consult the factory for further information and availability.
Pulse Output Kits
475-244-001
10-30 VDC
475-244-002
110/220 VAC
475-244-003
10-30VDC, 110VAC and 220 VAC
s1fmdl1sm-REV0509
Grounding The Pump
To be fully groundable, the pumps must be ATEX
Compliant. Refer to pump data sheet for ordering.
One eyelet is fastened to the pump hardware.
One eyelet is installed to a true earth ground.
(Requires a 5/16 or 8mm maximum diameter bolt)
This 8 foot long (244 centimeters) Ground
Strap part number 920-025-000, can be
ordered as a service item.
To reduce the risk of static electrical sparking,
this pump must be grounded. Check the
local electrical code for detailed grounding
instruction and the type of equipment required.
WARNING
Take action to prevent static
sparking. Fire or explosion can
result, especially when handling
flammable liquids. The pump,
piping, valves, containers or other
miscellaneous equipment must
be grounded.
s1fmdl1sm-REV0509
Declaration of Conformity
Warren Rupp®, IDEX AODD, Inc., 800 N. Main Street, P.O. Box 1568,
Mansfield, Ohio, 44901-1568 USA, certifies that Air-Operated
Double Diaphragm Pump Series: HDB, HDF, M Non-Metallic,
S Non-Metallic, M Metallic, S Metallic, T Series, G Series, U Series,
EH and SH High Pressure, W Series, SMA and SPA Submersibles,
and Tranquilizer Surge Supressors comply with the European
Community Directive 98/37/EC, Safety of Machinery. This product
has used Harmonized Standard EN 809, Pumps and Pump Units
for Liquids - Common Safety Requirements, to verify conformance.
Signature of authorized person
October 20, 2005
Date of issue
David Roseberry
Printed name of authorized person
Engineering Manager
Title
Revision level B
April 1, 2009
Date of revision

Model S1F Metallic Design Level 1

Transcription

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